Systems and methods for implementing multi-layer addressable curing of ultraviolet (UV) light curable inks for three dimensional (3D) printed parts and components

Abstract

A system and method are provided for implementing adjustable curing of layers of deposition materials, including ultraviolet (UV) light or photo curable ink layers, used in the formation and / or manufacture of three-dimensional (3D) printed parts, objects and components, particularly those parts, objects and components formed in 3D printers and additive material manufacturing systems such as 3D jetted ink printing systems. A multi-layer (or layer-by-layer) history of the deposited materials is developed by which to adjust an intensity of an addressable curing unit to provide complete curing to a particular layer without introducing damaging effects that may be caused by over curing the particular layer. The applied curing energy will differently penetrate a number of layers based on constitutions and / or colors of the individual layers in the number of layers to be penetrated. Discrete addressable curing of the individual layered components provides correct curing to the individual layers.

Description

BACKGROUND[0001]1. Field of the Disclosed Embodiments[0002]This disclosure relates to systems and methods for implementing adjustable curing of ultraviolet (UV) light or photo curable ink layers in the formation and / or manufacture of three-dimensional (3D) printed parts and components, particularly those parts and components formed in 3D jetted ink printing systems.[0003]2. Related Art[0004]Three-dimensional or 3D printing generally refers to a broad class of techniques (also referred to as “additive material manufacturing” or AM techniques) that are usable for producing three-dimensional parts, objects or components (“3D printed parts”) often through a repetitive layer-by-layer material deposition process. 3D printing techniques employ one or more processes that appear, in many respects, similar to well-known comparable processes for forming two-dimensional (2D) printed images on image receiving media substrates. The significant differences in the output structures produced by the ...

AI Technical Summary

Benefits of technology

[0010]Correct curing of 3D printed parts is a challenge that all UV ink 3D printers encounter. Curing thoroughly enough without over-curing is difficult with the wide range of UV ink colors available to 3D printers. Addressable curing is important in 2D image forming for, for example, maintaining formed color images. As an example, if a clearcoat ink is over cured, it can be caused to yellow in the curing process. Similarly, other colors may be “discolored” if over cured. This reduces image quality based on random discoloration of the materials deposited on the image receiving media substrate. If under cured, the deposited image materials may be caused to smudge, smear or the like, thereby also affecting image quality on the output images.

[0012]It may be advantageous to provide systems, methods, techniques, processes and schemes that can better assure proper curing of internal layering of an in-process 3D object, and a surface of a finished 3D output object without requiring a post-curing coating process.

[0016]Exemplary embodiments may employ a layer-by-layer history by which to adjust an intensity of an addressable curing unit to provide complete curing to a particular layer without introducing damaging effects that may be caused by over curing the particular layer. It may be appropriate to consult this layer-by-layer history because the applied light, including UV light, will differently penetrate a number of layers based on constitutions and / or colors of the individual layers in the number of layers to be penetrated by the light for curing. The light may penetrate, for example, twenty plus layers of clear ink, while only penetrating a few layers of black or other dark colored ink.

[0021]Exemplary embodiments may employ a layer-by-layer history by which to adjust an intensity of an addressable curing unit to provide complete curing to a particular layer without introducing damaging effects that may be caused by over curing the particular layer. It is appropriate to consult this layer-by-layer history because the applied light, including UV light, will differently penetrate a number of layers based on constitutions and / or colors of the individual layers in the number of layers. The light may penetrate, for example, twenty plus layers of clear ink, while only penetrating a few layers of black ink

Problems solved by technology

Correct curing of 3D printed parts is a challenge that all UV ink 3D printers encounter.

Curing thoroughly enough without over-curing is difficult with the wide range of UV ink colors available to 3D printers.

As an example, if a clearcoat ink is over cured, it can be caused to yellow in the curing process.

This reduces image quality based on random discoloration of the materials deposited on the image receiving media substrate.

If under cured, the deposited image materials may be caused to smudge, smear or the like, thereby also affecting image quality on the output images.

In 3D printing, there are additional issues.

These adversely affected properties may include strength and hardness.

Failure to surface cure the finished 3D output object may result in the introduction of defects into the surface of the finished 3D output object through simple post-processing handling and / or manipulation of the allegedly finished 3D output object.

Additionally, because certain of the deposition materials for producing 3D output objects are not necessarily bio-safe in an uncured state (e.g., “the ink is bad for your health”), hazards to handling personnel may be introduced by a failure to completely cure a surface of the finished 3D output object.

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